Weld training systems with resettable target tool images

ABSTRACT

Described herein are examples of weld training systems that show (e.g., transparent and/or translucent) “ghost” images of a welding tool on a display screen of a welding headgear to indicate target positions and/or target orientations of an actual welding tool. In some examples, the weld training systems may additionally “reset” the target tool image to a position closer to the actual welding tool if the target tool image gets too far away. The ability to “reset” the target tool image to a position closer to the actual welding tool may help in minimizing a risk that an operator  106  will overcompensate to try to catch up with the target tool image, which can be detrimental to the weld. Additionally, resetting the target tool image to a position closer the welding tool may allow an operator to better perceive and/or understand differences in orientation and/or other technique parameters.

TECHNICAL FIELD

The present disclosure generally relates to weld training systems and,more particularly, to weld training systems with resettable target toolimages.

BACKGROUND

The welding industry has a shortage of experienced and skilled operatorsavailable for welding jobs. Additionally, conventional training of newoperators requires live instruction from experienced operators, makingthe shortage of experienced operators available for welding jobs evengreater. As a result, training systems that simulate live instructionaltraining have been developed in order to help train new operatorswithout requiring live instruction from experienced operators.

Limitations and disadvantages of conventional and traditional approacheswill become apparent to one of skill in the art, through comparison ofsuch systems with the present disclosure as set forth in the remainderof the present application with reference to the drawings.

BRIEF SUMMARY

The present disclosure is directed to weld training systems withresettable target tool images, substantially as illustrated by and/ordescribed in connection with at least one of the figures, and as setforth more completely in the claims.

These and other advantages, aspects and novel features of the presentdisclosure, as well as details of an illustrated example thereof, willbe more fully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example of a weld training system, in accordance withaspects of this disclosure.

FIG. 2 a-2 b shows enlarged front and side views of a welding helmet ofthe weld training system of FIG. 1 , in accordance with aspects of thisdisclosure.

FIG. 3 is a block diagram showing example components andinterconnections of the weld training system of FIG. 1 , in accordancewith aspects of this disclosure.

FIG. 4 is a flow diagram illustrating an example operation of a weldtraining simulation process of the weld training system of FIG. 3 , inaccordance with aspects of this disclosure.

FIG. 5 is a flow diagram illustrating an example operation of a targettool image process of the weld training simulation process of FIG. 4 ,in accordance with aspects of this disclosure.

FIGS. 6 a-6 d show various examples of a display screen of the weldinghelmet of FIGS. 2 a-2 b during the target tool image process of FIG. 5 ,in accordance with aspects of this disclosure.

The figures are not necessarily to scale. Where appropriate, the same orsimilar reference numerals are used in the figures to refer to similaror identical elements.

DETAILED DESCRIPTION

Some examples of the present disclosure relate to weld training systemsthat show (e.g., transparent and/or translucent) “ghost” images of awelding tool (e.g., torch) on a display screen of a welding headgear tohelp guide a trainee through a welding operation. In some examples, the“ghost” images of the welding tool may indicate target positions and/ororientations for the actual welding tool being used by the trainee. Asthe “ghost” images indicate target positions/orientations of the weldingtool, the images are referred to herein as target tool images.

In some examples, the target tool images may serve as a guide to helpnew welding operators understand proper welding technique (e.g., travelspeed, contact tip to work distance, work angle, travel angle, aim,etc.) for a particular welding operation. In some examples, the targettool images may be shown on a display screen of a welding helmet and/orother headgear. By displaying the target tool image on a display screenof the helmet/headgear, a user wearing the helmet/headgear will be ableto easily see the target tool image in relation to the actual weldingtool, without having to look away from the welding operation.

In some examples, the weld training systems may additionally “reset” (orprovide an option to reset) the target tool image to an earlier and/orprior position if the target tool image gets too far from the weldingtool. This may help in situations where the travel speed of the targettool image substantially outpaces the travel speed of the actual weldingtool (or vice versa). In such situations, the relative orientations ofthe target tool image and actual welding tool may be difficult tocompare due to their distance, making the target tool image less helpfulas a training guide. Additionally, resetting the target tool image to aposition closer to the welding tool may minimize the possibility thatthe trainee will be tempted to overcompensate their travel speed (up ordown) in order to catch up with the target tool image; a practice whichmay be highly detrimental to the quality of the weld.

Some examples of the present disclosure relate to a non-transitorymachine readable medium comprising machine readable instructions which,when executed by a processor, cause the processor to: determine a firsttarget position and a first target orientation for a target tool imagebased on one or more target welding technique parameters; identify anactual position and an actual orientation of a welding tool based onsensor data received from a sensor of a welding headgear; compare theactual position of the welding tool with the first target position ofthe target tool image; and in response to determining the first targetposition of the target tool image is more than a threshold distance fromthe actual position of the welding tool: reset, or provide an option toreset, the first target position of the target tool image to a secondtarget position that is closer to the actual position of the weldingtool.

In some examples, the non-transitory machine readable medium furthercomprises machine readable instructions which, when executed by aprocessor, cause the processor to display the target tool image on adisplay screen of the welding headgear based on the first targetposition or the second target position. In some examples, thenon-transitory machine readable medium further comprises machinereadable instructions which, when executed by a processor, cause theprocessor to display a movement of the target tool image on the displayscreen at a travel speed that corresponds to an actual travel speed ofthe welding tool. In some examples, the non-transitory machine readablemedium further comprises machine readable instructions which, whenexecuted by a processor, cause the processor to negatively adjust awelding score in response to the first target position being reset.

In some examples, the welding score is determined based on a differencebetween the first target orientation of the target tool image and theactual orientation of the welding tool, as well as a number of times thefirst target position of the target tool image was reset. In someexamples, the one or more target welding technique parameters wererecorded during a previous welding operation. In some examples, thesecond target position of the target tool image corresponds to aposition that was recorded during the previous welding operation.

Some examples of the present disclosure relate to a welding headgear,comprising: a display screen; a sensor configured to detect sensor datarelating to a welding tool; and processing circuitry configured to:determine a first target position and a first target orientation for atarget tool image based on one or more target welding techniqueparameters, identify an actual position and an actual orientation of thewelding tool based on the sensor data, compare the actual position ofthe welding tool with the first target position of the target toolimage, and in response to determining the first target position of thetarget tool image is more than a threshold distance from the actualposition of the welding tool: reset, or provide an option to reset, thefirst target position of the target tool image to a second targetposition that is closer to the actual position of the welding tool.

In some examples, the processing circuitry is further configured to:identify an activation time of the welding tool or a length of a weldbead, determine the first target position and first target orientationfor the target tool image based on the one or more target weldingtechnique parameters as well as: the activation time of the weldingtool, or the length of the weld bead. In some examples, the one or moretarget welding technique parameters were recorded during a previouswelding operation, and the second target position of the target toolimage corresponds to a position of a previous welding tool that wasrecorded during the previous welding operation when a previous weld beadwas of a same length as the length of the weld bead. In some examplesthe welding headgear further comprises a helmet shell, the displayscreen, sensor, and processing circuitry being retained by the helmetshell.

In some examples, the one or more target welding technique parameterscomprise one or more of a torch position, torch orientation, torchtravel speed, torch travel direction, torch travel angle, work angle,contact tip to work distance, torch aim, or weld path characteristic,and the sensor comprises a camera sensor, optical sensor, infra-red (IR)sensor, thermal sensor, acoustic sensor, ultrasonic sensor, orelectromagnetic sensor. In some examples, the target tool imagecomprises an outline, transparent depiction, translucent depiction, orsemi-transparent depiction of the welding tool, a different weldingtool, or a welding consumable. In some examples, the processingcircuitry is further configured to: compare the actual position andactual orientation of the welding tool with the first target positionand first target orientation of the target tool image, and in responseto determining the actual position and actual orientation of the weldingtool match the first target position and first target orientation of thetarget tool image, providing an effect that affirms that the weldingtool is properly positioned and oriented.

Some examples of the present disclosure relate to a method of guiding awelding operator, comprising: determining, via processing circuitry of awelding headgear, a first target position and a first target orientationfor a target tool image based on one or more target welding techniqueparameters; identifying an actual position and an actual orientation ofa welding tool based on sensor data received from a sensor of thewelding headgear; comparing the actual position of the welding tool withthe first target position of the target tool image; and in response todetermining the first target position of the target tool image is morethan a threshold distance from the actual position of the welding tool:resetting, or providing an option to reset, the first target position ofthe target tool image to a second target position that is closer to theactual position of the welding tool.

In some examples, the method further comprises displaying the targettool image on a display screen of the welding headgear based on thefirst target position or second target position. In some examples, themethod further comprises negatively adjusting a welding score inresponse to the first target tool position being reset, and displayingthe welding score on the display screen. In some examples, the methodfurther comprises displaying a movement of the target tool image on thedisplay screen at a travel speed that corresponds to an actual travelspeed of the welding tool.

In some examples, the one or more target welding technique parameterscomprise one or more of a torch position, torch orientation, torchtravel speed, torch travel direction, torch travel angle, work angle,contact tip to work distance, torch aim, or weld path characteristic,the sensor comprises a camera sensor, optical sensor, infra-red (IR)sensor, thermal sensor, acoustic sensor, ultrasonic sensor, orelectromagnetic sensor, and the target tool image comprises an outline,transparent depiction, translucent depiction, or semi-transparentdepiction of the welding tool, a different welding tool, or a weldingconsumable. In some examples, the method further comprises comparing theactual position and actual orientation of the welding tool with thefirst target position and first target orientation of the target toolimage; and in response to determining the actual position and actualorientation of the welding tool match the first target position andfirst target orientation of the target tool image, providing an effect,via a user interface of the welding headgear, that affirms that thewelding tool is properly positioned and oriented.

FIG. 1 a shows an example of a weld training system 100. As shown, theweld training system 100 includes welding-type equipment 102 connected(e.g., electrically) with a welding-type tool 104. In the example ofFIG. 1 , an operator 106 wearing a welding helmet 200 is using thewelding-type tool 104 to perform a welding-type operation on a workpiece108 sitting on a welding bench 110. An observer 112 holding anobservation device 150 is shown watching the operator 106 perform thewelding-type operation.

While not shown in the example of FIG. 1 for the sake of simplicity, insome examples, the welding-type equipment 102 may also be (e.g.,electrically) connected to the welding bench 110 and/or workpiece 108.Though only one observer 112 is shown in the example of FIG. 1 for thesake of simplicity, in some examples there may be several observers 112with several different observation devices 150. While shown as ahandheld mobile device (e.g., smartphone, tablet, etc.) in the exampleof FIG. 1 , in some examples, the observation device 150 may instead bea welding helmet 200 or other device.

In some examples, the welding helmet 200 worn by the operator 106 inFIG. 1 may implement a weld training simulator configured to conduct aweld training simulation. In some examples, the welding helmet 200 maybe configured to conduct a weld training simulation that is a virtual,augmented, or mixed reality weld training simulation. In some examples,the welding helmet 200 may conduct the weld training simulation byoutputting simulation stimuli (e.g., visual effects, audio effects,haptic effects, and/or other sensory stimulations perceptible to theoperator 106) while still allowing the operator 106 to perceive some orall of the real world. The stimuli output by the welding helmet 200 mayoverlap with (and/or augment) real world stimuli, resulting in anaugmented, mixed, mediated, or simulated reality.

In some examples, the welding helmet 200 may simulate various stimulithat occur during live, real world, welding-type operations, such as,for example the sight, sound, and/or feel of a welding arc, a moltenweld puddle, a weld bead, welding fumes, spatter, sparks, a welding-typetool, a workpiece material, and/or an auto-darkening filter (ADF). Inthis way, the welding helmet 200 can provide the operator 106 with asimulated version of a live welding-type operation. In some examples,the welding helmet 200 may instead be used during an actual livewelding-type operation. Whether used during live, real world,welding-type operations, or simulated welding-type operations, thewelding helmet 200 may provide various stimuli to help guide theoperator 106 through the welding-type operation.

In some examples, the welding helmet 200 may provide stimuli in the formof real time feedback. For example, the welding helmet 200 may providefeedback to the operator 106 with respect to a welding technique of theoperator 106, welding parameters set by the operator 106, and/or otheraspects of the weld training system 100. In some examples, the feedbackmay help to guide a new and/or less experienced operator 106 inunderstanding how to perform the welding operation.

In order to conduct the weld training simulation convincingly, thewelding helmet 200 may track the position and/or orientation of certainitems. For example, the welding helmet 200 may track the position and/ororientation of the workpiece 108, the welding bench 110, thewelding-type tool 104, and/or certain portions of the welding-type tool104 (e.g., the nozzle, contact tip, etc.). In examples where livewelding occurs, the welding helmet 200 may track the position and/ororientation of a welding arc. In some examples, the welding helmet 200may track the position and/or orientation of itself, which may, in somesituations, help the welding helmet 200 to distinguish between movementof the welding helmet 200 and movement of items tracked by the weldinghelmet 200. In some examples, the welding helmet 200 may track positionsand/or orientations using helmet sensors 202, discussed further belowwith respect to FIGS. 2-3 .

In some examples, markers 114 may assist the welding helmet 200 and/orweld training system 100 in tracking the position and/or orientation ofthe welding-type tool 104. For example, the markers 114 may be easilyrecognizable by the welding helmet 200 in (e.g., image) data captured bythe helmet sensors 202, and thus assist in recognition of thewelding-type tool 104. In some examples, the markers 114 may assist inidentifying and/or recognizing particular portions of the welding-typetool 104.

For example, the markers 114 may define (and/or may be calibrated todefine) a recognizable and/or unique geometric configuration (and/orrigid body). In some examples, this geometric configuration (and/orrigid body) can be correlated (e.g., in memory) with a known (e.g.,stored in memory) structural configuration and/or model of thewelding-type tool 104. Thus, by identifying and/or tracking theparticular geometric configuration of markers 114, the weld trainingsystem 100 may be able to identify and/or track the structuralconfiguration of the welding-type tool 104; including particularportions (e.g., nozzle, neck, handle, etc.) of the structuralconfiguration.

In some examples, the welding-type tool 104 may include at least threemarkers 114 fixed to the welding-type tool 104 relative to one anotherin a single plane, and a fourth marker 114 fixed to the welding-typetool 104 in a different (e.g., adjacent) plane, to define a rigid body.While a certain number of markers 114 are shown in the example of FIG. 1attached to the handle, neck, and nozzle of the welding-type tool 104for the purposes of illustration, in some examples more or fewer markers114 may be attached to the handle, neck, nozzle, and/or other portionsof the welding-type tool 104.

In some examples, the welding-type tool 104 may include no markers 114.In such examples, the weld training system 100 may instead use objectrecognition, computer vision, and/or other image processing techniquesto identify, recognize, and/or track the welding-type tool 104.

While depicted in FIG. 1 as a welding torch or gun configured for gasmetal arc welding (GMAW), in some examples, the welding-type tool 104may instead be a different welding-type tool 104. For example, thewelding-type tool 104 may be an electrode holder (i.e., stinger)configured for shielded metal arc welding (SMAW), a torch and/or fillerrod configured for gas tungsten arc welding (GTAW), a welding gunconfigured for flux-cored arc welding (FCAW), and/or a plasma cutter. Insome examples, the welding-type tool 104 may be a mock welding-typetool, and/or be configured for mock (as opposed to live) welding-typeoperations.

In the example of FIG. 1 , the welding-type tool 104 is connected towelding-type equipment 102. In examples where live welding-typeoperations are conducted, the welding-type equipment 102 may providewelding-type power and/or consumables to the welding-type tool 104,and/or information to the welding helmet 200. In some examples wherelive welding-type operations are conducted, the welding-type tool 104may transmit one or more signals to the welding-type equipment 102(and/or welding helmet 200 and/or observation device 150) when activated(e.g., via trigger pull, foot pedal press, etc.). In response to theactivation signal(s), the welding-type equipment 102 may outputwelding-type power and/or consumables (e.g., wire and gas) to thewelding-type tool 104.

In some examples where simulated welding-type operations are conducted,the welding-type tool 104 may still transmit one or more signals to thewelding-type equipment 102 (and/or welding helmet 200 and/or observationdevice 150) when activated. However, the welding-type equipment 102 mayjust provide activation information to the welding helmet 200 (and/orobservation device 150) in response to the activation signals, ratherthan outputting power or consumables. In some examples where simulatedwelding-type operations are conducted, the welding-type equipment 102may comprise mock welding-type equipment and/or a computational system(e.g., desktop, laptop, etc.). In some examples where simulatedwelding-type operations are conducted, the welding-type equipment 102may be omitted altogether.

In the example of FIG. 1 , the welding-type equipment 106 comprises awelding-type power supply 118, wire feeder 120, and gas supply 122. Insome live welding examples, the wire feeder 120 may be configured tofeed wire to the welding-type tool 104. In some live welding examples,the gas supply 122 may be configured to route shielding gas to thewelding-type tool 104.

In the example of FIG. 1 , the power supply 118 includes powercommunication circuitry 124, power control circuitry 126, and powerconversion circuitry 128 interconnected with one another. In someexamples, the power conversion circuitry 128 may be configured toreceive input power (e.g., from a generator, a battery, mains power,etc.) and convert the input power to welding-type output power, such asmight be suitable for use by the welding-type tool 104 for welding-typeoperations. In some examples, the power control circuitry 126 may beconfigured to control operation of the communication circuitry 124,power conversion circuitry 128, wire feeder 120, and/or gas supply 122(e.g. via one or more control signals) in accordance with one or morewelding parameters.

In the example of FIG. 1 , the welding-type equipment 102 furtherincludes an operator interface 130. In some examples, the operatorinterface 130 may comprise one or more display screens, touch screens,knobs, buttons, levers, switches, microphones, speakers, lights, and/orother mechanisms through which an operator 106 may provide input to,and/or receive output from, the welding-type equipment. For example, anoperator 106 may use the operator interface 130 to input one or morewelding parameters (e.g., target voltage, current, wire feed speed,wire/filler type, wire/filler diameter, gas type, gas flow rate,welding-type process, material type of workpiece 108, position ofwelding-type process, joint position, joint type, jointgeometry/thickness, etc.). As another example, the operator 106 may usethe operator interface 130 to view and/or otherwise understand thecurrent welding parameters of the welding-type equipment 102.

While shown as part of the power supply 118 in FIG. 1 , in someexamples, the operator interface 130, power control circuitry 126,and/or power communication circuitry 124 (and/or some othercontrol/communication circuitry) may be part of the wire feeder 120and/or gas supply 122. In some examples, the power communicationcircuitry 124 may be configured to facilitate communication with thewelding-type tool 104, welding helmet 200, observation device 150,and/or welding helmet 200.

FIGS. 2 a-2 b show example enlarged front and side view of the weldinghelmet 200. While shown as a welding helmet 200 in the examples of FIGS.2 a-2 b , in some examples, the welding helmet 200 may be a differentsort of headgear. For example, the welding helmet 200 may instead beimplemented via goggles, a non-welding helmet, a visor, and/or otherappropriate wearables.

In the example of FIGS. 2 a-2 b , the welding helmet 200 comprises ahelmet shell 201 attached to a suspension 204. As shown, the suspension204 comprises several straps and/or bands configured to wrap around thehead of an operator 106. The straps are connected to one another and tothe helmet shell 201 at least at two side attachment points on eitherside of the head of the operator 106. In some examples, the helmet 200may be configured to rotate and/or pivot about the side attachmentpoints to transition between raised and lowered positions.

In the examples of FIGS. 2 a-2 b , the welding helmet 200 also includesa lens assembly 206 fixed to (and/or integrated into) a front portion ofthe helmet shell 201 at approximately eye level. In some examples, thelens assembly 206 may comprise a mobile device (e.g., smartphone,tablet, etc.). In some examples, the lens assembly 206 may include acover lens, an auto-darkening filter (ADF), and/or one or more displayscreens 602 (see, e.g., FIGS. 6 a-6 d ). In some examples, the coverlens may be (e.g., partially or fully) transparent and/or configured toallow an operator 106 to see through the cover lens and/or view thesurrounding environment.

In some examples, the display screen(s) 602 of the lens assembly 206 maycomprise one or more near-eye displays. In some examples, the displayscreen(s) 602 may be semi-transparent and/or configured to overlayinformation (e.g., virtual/simulated/holographic objects, guidance,technique feedback, technique parameters, welding parameters, messages,etc.) onto at least part of cover lens (and/or lens assembly 206). Insome examples, the display screen(s) 602 may be integrated into safetyglasses attached to (and/or in communication with) the welding helmet200.

In some examples, a display screen(s) 602 may cover the entire coverlens (and/or lens assembly 206). In some examples where the displayscreen(s) 602 covers the entire cover lens (and/or lens assembly 206),the ADF may be omitted. In some examples, a display screen 602 may coveronly a portion of the cover lens (and/or lens assembly 206), so as to bevisible on only one side (e.g., to only one eye). In some examples,providing the display screen(s) 602 over both sides of the lens assembly206 (and/or eyes) may make stereoscopic display possible, which may makeit possible to display images that appear to have more depth. In someexamples, a display screen may be positioned at and/or over a peripheryof the lens assembly 206, so as to be less distracting.

In some examples, the display screen(s) 602 may be configured to displaysimulation stimuli and/or feedback. For example, the display screen(s)602 may display stimuli simulating effects of the ADF, informationregarding welding parameters of the welding equipment 102, and/orfeedback regarding welding technique parameters (e.g., contact tip towork distance, travel speed, travel angle, work angle, aim, etc.). Insome examples, the display screen(s) 602 may display feedback regardingwelding parameters as compared to expected welding parameters. In someexamples, the display screen(s) 602 may display feedback regardingtarget welding technique parameters in the form of one or more (e.g.,transparent and/or translucent) target tool images, depicting targetpositions and/or orientations of the welding-type tool 104. In someexamples, feedback may be instead (or additionally) output via otherhelmet I/O devices 208.

In the examples of FIGS. 2 a-2 b , the welding helmet 200 includeshelmet input/output (I/O) devices 208. In some examples, the helmet I/Odevices 208 are devices through which an operator 106 may provide inputto, and/or receive output from, the welding helmet 200. In someexamples, the I/O devices 208 may include knobs, buttons, levers,switches, touch screens, microphones, speakers, haptic devices, lights(e.g., LEDs), and/or other appropriate I/O devices 208. In someexamples, the display screen(s) 602 may be considered part of the helmetI/O devices 208. In some examples, settings of the weld trainingsimulation may be controlled and/or presented to the operator 106 viathe helmet I/O devices 208. While shown as being retained on an externalsurface of the helmet shell 201 in the examples of FIGS. 2 a-2 b for thepurposes of illustration, in some examples, some I/O devices 208 mayalso be retained on an internal surface of the helmet shell 201.

In the examples of FIGS. 2 a-2 b , the welding helmet 200 also includeshelmet sensors 202. Four helmet sensors 202 are shown as part of thelens assembly 206, while a fifth helmet sensor 202 is shown attached toa rear of the helmet shell 201, separate from the lens assembly 206. Insome examples, the welding helmet 200 may include more or fewer helmetsensors 202. In some examples, the four helmet sensors 202 of the lensassembly 206 may be used to track the six degree of freedom (DOF)position and/or orientation of items for the weld training simulation,while the fifth helmet sensor 202 may be used to track the positionand/or orientation of the welding helmet 200 itself.

In some examples, the helmet sensors 202 of the welding helmet 200 maybe fixed relative to each other, the helmet shell 201, and/or thedisplay screen(s). In some examples, the relative positions of thehelmet sensors 202 of the welding helmet 200 may be known, stored,entered manually, and/or automatically detected during a calibrationprocedure. In some examples, each helmet sensor 202 may comprise one ormore camera sensors, optical sensors, infra-red (IR) sensors, thermalsensors, acoustic sensors, ultrasonic sensors, electromagnetic sensors,inertial measurement sensors, accelerometers, gyroscopes, magnetometers,and/or other appropriate types of sensors.

In the examples of FIGS. 2 a-2 b , the welding helmet 200 furtherincludes helmet circuitry 218 and a helmet power source 216. In someexamples, the helmet circuitry 218 and helmet power source 216 may beinternal to the helmet shell 202. In some examples, the helmet powersource 216 may provide electrical power to the components of the weldinghelmet 200. In some examples, the power source 216 may comprise one ormore batteries, solar panels, and/or energy harvesting devices. In someexamples, one or more components of the welding helmet 200 may have aseparate power source from which to draw power. In some examples, thehelmet circuitry 218 may support, drive, and/or facilitate operation ofthe welding helmet 200. In some examples, the power source 216 and/orhelmet circuitry 218 may be part of the lens assembly 206.

FIG. 3 is a block diagram showing components and interconnections of theweld training system 100. In particular, FIG. 3 shows more detailedcomponents and interconnections of the welding helmet 200 and helmetcircuitry 218. While not shown for the sake of simplicity, the weldinghelmet 200 may further include power source 216 connected with (and/orproviding electrical power to) some or all of the components of thewelding helmet 200.

In the example of FIG. 3 , the welding helmet 200 is in communicationwith the welding-type tool 104, the welding equipment 102, one or moreother welding helmets 200, and one or more observation devices 150. Insome examples, each observation device 150 may have components similarto that of the welding helmet 200 (e.g., sensors, I/O devices,circuitry, power, etc.). In some examples, each observation device 150may have a structure similar (or identical) to that which is disclosedin U.S. patent application Ser. No. 17/209,755, filed Mar. 23, 2021,entitled “Welding Simulation Systems with Observation Devices,” which ishereby incorporated by reference in its entirety.

In the example of FIG. 3 , the welding helmet 200 includes one or morehelmet sensors 202, helmet I/O devices 208, and helmet circuitry 218. Asshown, the helmet circuitry 218 includes helmet memory circuitry 302,helmet processing circuitry 304, helmet communication circuitry 306, andhelmet I/O circuitry 308 interconnected with one another via a commonelectrical bus.

In some examples, the helmet I/O circuitry 308 may comprise one or moredrivers for the helmet I/O devices 208. In some examples, the helmet I/Ocircuitry 308 may be configured to generate one or more signalsrepresentative of input received via the helmet I/O device(s) 208, andprovide the signal(s) to the bus. In some examples, the helmet I/Ocircuitry 308 may also be configured to control the helmet I/O device(s)208 to generate one or more outputs in response to one or more signals(e.g., received via the bus).

In some examples, the helmet communication circuitry 306 may include oneor more wireless adapters, wireless cards, cable adapters, wireadapters, dongles, radio frequency (RF) devices, wireless communicationdevices, Bluetooth devices, IEEE 802.11-compliant devices, WiFi devices,cellular devices, GPS devices, Ethernet ports, network ports, lightningcable ports, cable ports, etc. In some examples, the helmetcommunication circuitry 306 may be configured to facilitatecommunication via one or more wired media and/or protocols (e.g.,Ethernet cable(s), universal serial bus cable(s), etc.) and/or wirelessmediums and/or protocols (e.g., cellular communication, general packetradio service (GPRS), near field communication (NFC), ultra highfrequency radio waves (commonly known as Bluetooth), IEEE 802.11x,Zigbee, HART, LTE, Z-Wave, WirelessHD, WiGig, etc.). In some examples,the helmet communication circuitry 306 may be coupled to one or moreantennas to facilitate wireless communication.

In some examples, the helmet communication circuitry 306 may beconfigured to facilitate communications of the welding helmet 200. Insome examples, the helmet communication circuitry 306 may receive one ormore signals (e.g., from the welding-type tool 104, welding-typeequipment 102, etc.) decode the signal(s), and provide the decoded datato the electrical bus. As another example, the helmet communicationcircuitry 306 may receive one or more signals from the electrical bus(e.g., representative of one or more inputs received via the helmet I/Ocircuitry 308) encode the signal(s), and transmit the encoded signal(s)to an external device (e.g., welding-type tool 104, welding-typeequipment 102, etc.).

In some examples, the helmet processing circuitry 304 may comprise oneor more processors, controllers, and/or graphical processing units(GPUs). In some examples, the helmet processing circuitry 304 maycomprise one or more drivers for the helmet sensors 202. In someexamples, the helmet processing circuitry 304 may be configured toexecute machine readable instructions stored in the helmet memorycircuitry 302.

In the example of FIG. 3 , the helmet memory circuitry 302 includes(and/or stores) a weld training simulation process 400. As shown, theweld training simulation process 400 includes a target tool imageprocess 500. In some examples, the weld training simulation process 400and/or target tool image process 500 may comprise machine readableinstructions configured for execution by the helmet processing circuitry304.

In some examples, the weld training simulation process 400 may processsensor data captured by helmet sensors 202 and track the 6 DOF positionand/or orientation of the welding-type tool 104, workpiece(s) 108,welding helmet 200, and/or other relevant items using the capturedsensor data. In some examples, the weld training simulation process 400may use the 6 DOF position(s) and/or orientation(s) (e.g., inconjunction with other information) to simulate a welding-typeoperation, workpiece material, etc. In some examples, the weld trainingsimulation process 400 may use the 6 DOF position(s) and/ororientation(s) (e.g., in conjunction with other information) todetermine what simulation stimuli to output, as well as how and/or whereto output, in order to effectively guide the operator 106 through thewelding-type operation.

In some examples, the weld training simulation process 400 may executethe target tool image (e.g., sub) process 500 to help guide the operator106 through the welding-type operation. In some examples, the targettool image process 500 may show a “ghost” (e.g., transparent and/ortranslucent) image of a welding-type tool on the display screen(s) 602of the welding helmet 200 to indicate target positions and/ororientations for the actual welding-type tool 104. In some examples, thetarget tool image process 500 may use the 6 DOF position(s) and/ororientation(s) (e.g., in conjunction with other information) todetermine how and/or where to output the target tool image, so as toeffectively guide the operator 106 through the welding-type operation.

FIG. 4 is a flowchart illustrating example operation of the weldtraining simulation process 400 of the welding helmet 200. In someexamples, an observation device 150 may operate a modified form of theweld training simulation process 400 and/or coordinate with the weldtraining simulation process (e.g., as described in U.S. patentapplication Ser. No. 17/209,755, filed Mar. 23, 2021, entitled “WeldingSimulation Systems with Observation Devices”).

In the example of FIG. 4 , the weld training simulation process 400begins at block 402, where the weld training simulation process 400configures a weld training session. In some examples, configuring theweld training session may comprise configuring the welding helmet 200 soit can communicate with the welding-type equipment 102, the welding-typetool 104, other welding helmets 200, and/or one or more observationdevices 150.

In some examples, configuring the weld training session may compriseconfiguring welding parameters. In some examples, configuring the weldtraining session may comprise the welding helmet 200 receiving thewelding parameters from the welding-type equipment 102. In someexamples, configuring the weld training session may comprise calibratingthe welding helmet 200, such as, for example, calibrating the spatialrelationship between the helmet sensors 202, and/or between the helmetsensors 202 and the display screen(s) 602 of the welding helmet 200.

In some examples, configuring the weld training session may comprise oneor more selections. For example, selecting a (e.g., type of) weldtraining exercise, a (e.g., type of) welding-type operation, a (e.g.,type of) welding-type tool 104, a (e.g., type of) the welding-typeequipment 102, one or more (e.g., types of) markers 114, one or moreweld training session parameters, desired feedback, and/or desiredstimuli. In some examples, configuring the weld training session maycomprise selecting whether live or mock welding-type operations will beconducted.

In some examples, an operator 106 may provide one or more inputs (e.g.,via the helmet I/O device(s) 208) to configure the weld trainingsimulation process 400. In some examples, the welding helmet 200 maysynchronize and/or communicate with one or more observation devices 150and/or other welding helmets 200 to configure the weld trainingsimulation process 400 at block 402. In some examples, the weld trainingsimulation process 400 may store the configuration data in helmet memorycircuitry 302.

After the configurations are complete, the weld training simulationprocess 400 may begin a weld training session. In some examples, theweld training session may begin in response to an input from an operator106 (e.g., via the helmet I/O device(s) 208). In some examples, the weldtraining session may begin in response to one or more signals receivedfrom the welding-type tool 104, welding-type equipment 102, observationdevice(s) 150, and/or one or more other welding simulators 300. In someexamples, the weld training simulation process 400 may send one or moresignals to other welding helmets 200 and/or observation devices 150indicating when the weld training session has started.

In the example of FIG. 4 , the weld training simulation process 400proceeds to block 404 after block 402. At block 404, the weld trainingsimulation process 400 obtains sensor data from the perspective of thewelding helmet 200 via the helmet sensor(s) 202 of the welding helmet200. Using the sensor data, the weld training simulation process 400determines the position(s) and/or orientation(s) of items tracked by theweld training simulation process 400 (e.g., the welding-type tool 104,workpiece(s) 108, arc, etc.) in 6 DOF (e.g., x, y, z coordinates andyaw, pitch, roll angles). In some examples, the weld training simulationprocess 400 may also obtain sensor data from the perspective of anobservation device 150 and/or another welding helmet 200 in order toappropriately provide renderings from those perspectives (e.g., asfurther described in U.S. patent application Ser. No. 17/209,755, filedMar. 23, 2021, entitled “Welding Simulation Systems with ObservationDevices”).

In the example of FIG. 4 , the weld training simulation process 400proceeds to block 406 after block 404. At block 406, the weld trainingsimulation process 400 identifies an activation state of thewelding-type tool 104. In some examples, the weld training simulationprocess 400 may determine the activation state based on sensor data. Forexample, one or more markers 114 on the welding-type tool 104 may changestate (e.g., from invisible to visible, lit to unlit, static toblinking, blinking at a first frequency to blinking at a secondfrequency, etc.) when the welding-type tool 104 is activated.

In some examples, the weld training simulation process 400 may determinethe activation state based on position/orientation information. Forexample, the weld training simulation process 400 may conclude that thewelding-type tool 104 is activated if the welding-type tool 104 (and/ora nozzle, contact tip, etc. of the welding-type tool 104) is within athreshold distance of a workpiece 108. In some examples, the weldtraining simulation process 400 may determine the activation state ofthe welding-type tool 104 based on one or more signals received from thewelding-type tool 104, the welding-type equipment 102, and/or anotherwelding helmet 200. For example, the welding-type tool 104 may send oneor more signals to the welding-type equipment 102 when the welding-typetool is activated (and/or deactivated), and the welding-type equipment102 may send one or more (identical or different) signals to the weldinghelmet 200. As another example, the welding-type tool 104 may send theone or more signals directly to the welding helmet 200. As anotherexample, another welding helmet 200 that has determined the activationstate may send one or more signals representative of the activationstate.

In some examples, the weld training simulation process 400 may useconfiguration information from block 402 (e.g., type(s) of welding-typetool 104 and/or marker(s) 114) to determine the activation state. Forexamples, the weld training simulation process 400 may expect to receivean activation signal from the welding-type tool 104 for certainconfigurations, and expect to receive an activation signal from thewelding-type equipment 102 for other configurations. In some examples,the weld training simulation process 400 may expect to determineactivation state purely from position/orientation information in certainother configurations.

In the example of FIG. 4 , the weld training simulation process 400proceeds to block 408 after block 406. At block 408, the weld trainingsimulation process 400 determines (and/or outputs) one or more weldingtechnique parameters. In some examples, the weld training simulationprocess 400 may determine the welding technique parameters based onconfiguration data, sensor data, position and/or orientationinformation, and/or the activation state of the welding-type tool 104.In some examples, welding technique parameters may be further determinedbased on sensor data, and/or position/orientation data relating to otherobjects tracked by the weld training simulation process 400. In someexamples, the weld training simulation process 400 may determine a weldtraining score for the operator 106 based on how closely one or more ofthe welding technique parameters (and/or other welding parameters) matchone or more expected welding technique parameters (and/or other weldingparameters).

In some examples, the welding technique parameters may include one ormore weld bead/path characteristics, such as, for example, a length,straightness, weave, whip, and/or position of the weld bead/path, and/ora distance between weld beads/paths. In some examples, data relating tothe movement (and/or activation) of the welding-type tool 104 along theweld path and/or joint may be evaluated to determine the weld bead/pathcharacteristics.

In the example of FIG. 4 , the weld training simulation process 400proceeds to block 410 after block 408. At block 410, the weld trainingsimulation process 400 generates simulation stimuli. In some examples,the simulation stimuli may include visual, audio, and/or haptic stimuli.For example, the simulation stimuli may simulate the sight, sound,and/or feel of an ADF, a welding-type tool 104, workpiece 108 (e.g.,material), welding arc, weld puddle, weld bead, and/or welding fumes. Insome examples, simulation stimuli may indicate welding parameterinformation, welding technique parameter information, score information,and/or feedback as to how to adjust and/or improve welding parametersand/or welding technique parameters. In some examples, simulationstimuli may be output via the helmet I/O devices 208.

In the example of FIG. 4 , the target tool image process 500 is shown aspart of block 410 of the weld training simulation process 400. In someexamples, the target tool image process 500 may execute as part of block410. In some examples, the target tool image process 500 may provide aspecific form of stimuli and/or feedback as part of block 410. Inparticular, the target tool image process 500 may show target toolimages 604 on the display screen(s) 602 of the welding helmet 200 toindicate target positions and/or orientations for the actualwelding-type tool 104 and help the operator 106 (see, e.g., FIGS. 6 a-6d ). The target tool image process 500 executed at block 410 isdiscussed in detail further below.

In the example of FIG. 4 , the weld training simulation process 400proceeds to block 412 after block 410. At block 412, the weld trainingsimulation process 400 records details (e.g., technique parameters,welding parameters, 6 DOF position/orientation data) of the weldtraining session so far. In some examples, the details may be saved inhelmet memory circuitry 302, and/or stored in cache until the end of thewelding-type operation then saved in helmet memory circuitry 302. Insome examples, these details may be used at a later date by the targettool image process 500 to create and/or control the target tool images604.

In the example of FIG. 4 , the weld training simulation process 400proceeds to block 414 after block 412. At block 414, the weld trainingsimulation process 400 determines whether the present welding-typeoperation (and/or training session) is over. In some examples, thedetermination may be made based on one or more inputs received (or notreceived) via the helmet I/O devices 208 and/or helmet communicationcircuitry 306. As shown, the weld training simulation process 400returns to block 404 if the weld training simulation process 400determines that the present welding-type operation (and/or trainingsimulation) is not over. The weld training simulation process 400 endsafter block 414 if the weld training simulation process 400 determinesthat the present welding-type operation (and/or training session) isover (though, in some examples, the weld training simulation process 400may instead return to block 402). In some examples, the weld trainingsimulation process 400 may communicate the determination at block 414 tosynched observation devices 150 and/or welding helmets 200.

FIG. 5 is a flowchart illustrating example operation of the target toolimage process 500. In some examples, the target tool image process 500may provide a specific form of stimuli and/or feedback to help guide anoperator 106. In particular, the target tool image process 500 may showa (e.g., transparent and/or translucent) target tool image 604 toindicate target positions and/or orientations for the actualwelding-type tool 104 (see, e.g., FIGS. 6 a-6 d ). In some examples, thetarget tool images 604 may be shown on the display screen(s) 602 of thewelding helmet 200 and/or other headgear, so that a user wearing thehelmet/headgear can easily see the target tool image 604 in relation tothe actual welding-type tool 104 they are holding. In this way, a newwelding operator 106 may be trained on proper welding technique withoutrequiring an experienced operator to be present for live instruction.

In some examples, the target tool image process 500 may additionally“reset” (or provide an option to reset) the target tool image 604 to anearlier/later (and/or prior/subsequent) position if it gets too far awayfrom the actual position of the welding-type tool 104. This may help insituations where the travel speed of the target tool image 604substantially outpaces the travel speed of the actual welding-type tool104 (or vice versa), and the resulting distance makes differencesbetween the relative orientations more difficult to discern.Additionally, resetting the target tool image 604 to a position closerto the welding-type tool 104 may lessen the possibility that theoperators 106 will be tempted to drastically increase/decrease theirtravel speed in order to catch up with the target tool image 604; apractice which may be highly detrimental to the quality of the weld.

In the example of FIG. 5 , the target tool image process 500 begins atblock 502, where the target tool image process 500 obtains targetwelding technique parameters (e.g., contact tip to work distance, travelspeed, travel angle, work angle, aim, position, orientation, etc.). Insome examples, the target welding technique parameters may have beenrecorded during a prior weld training simulation process 400 (e.g., atblock 412). In some examples, the target welding technique parametersmay be determined by the target tool image process 500 based on datarecorded during a prior weld training simulation process 400. In someexamples, the target welding technique parameters may be manuallyentered (e.g., by an administrator).

In some examples, particular target welding technique parameters may betied to a particular time (e.g., of a welding-type operation and/orclock) and/or position (e.g., relative to workpiece, weld path, worldcoordinates, etc.). This might allow the target tool image process 500to determine, for example, particular target welding techniqueparameters for x seconds into the welding operation, or for ycentimeters along the weld bead/path.

In some examples, the target welding technique parameters may bemodified and/or customized at block 502. For example, the target weldingtechnique parameters may be modified and/or customized to start/end atparticular position(s)/time(s), which may be useful if the operator 106only wants guidance for one or more particular portions of the weldingoperation. As another example, the travel speed may be modified to beslower (e.g., ½ or ¼ speed) or faster (2×, 4×, etc.) than what wasoriginally recorded. In some examples, setting a slower/faster speed maymake it easier for a new operator 106 to stay close to the target toolimage 604, which has certain advantages, as explained above.

As another example, the target welding technique parameters may bemodified and/or customized to have a travel speed that is always equalto the travel speed of the welding-type tool 104. In some examples, thismay ensure the target tool image 604 never outpaces the welding-typetool 104, which has certain advantages, as explained above. As anotherexample, the target welding technique parameters may be modified and/orcustomized to be determined by position rather than time. This mayensure that the target tool image 604 is always shown at the sameposition along the weld bead/path as the welding-type tool 104,effectively eliminating the risk that the target tool image 604 outpacesthe welding-type tool 104.

In some examples, other parameters of the target tool image process 500may be modified and/or customized at block 502 as well. For example, thelook and/or feel of the target tool image 604 itself may be customized(e.g., size, shape, color, effects, etc.). In some examples, the type oftool the target tool image 604 depicts (e.g., in size, shape, etc.) maybe customized. In some examples, in the absence of customization, thetype of tool the target tool image 604 depicts may default to be thetype of tool used by the operator 106, or the type of tool used when thetarget welding technique parameters were first recorded. While referredto as a target tool image for the sake of simplicity, in some examples,the target tool image 604 may depict a welding consumable (e.g.,electrode, filler rod, etc.) as well as, or instead of, a welding-typetool 104. In some examples, the parameters of the target tool imageprocess 500 may be stored in helmet memory circuitry 302.

In the example of FIG. 5 , the target tool image process 500 proceeds toblock 504 after block 502. At block 504, the target tool image process500 identifies a position and/or orientation for the target tool image604. In some examples, the position and/or orientation of the targettool image 604 may be identified/determined based on the sensor dataand/or position/orientation data that was obtained and/or determined inthe weld training simulation process 400 (e.g., at block 404). In someexamples, the position and/or orientation of the target tool image 604may also be based on the target welding technique parameters. In someexamples, the position and/or orientation of the target tool image 604may be identified/determined relative to the welding helmet 200, theworkpiece 108, the welding-type tool 104, and/or some other object.

In some examples, the position and/or orientation of the target toolimage 604 may also be based on timing and/or positional information. Forexample, the position and/or orientation of the target tool image 604may be based on the amount of time the welding-type tool 104 has beenactivated (e.g., arc time). As another example, the position and/ororientation of the target tool image 604 may be based on the most recentposition of the welding-type tool 104 along the weld path when it wasactivated. As another example, the position and/or orientation of thetarget tool image 604 may be based on the length (and/or other profileinformation) of the weld bead/path that has been produced during thewelding operation so far.

In the example of FIG. 5 , the target tool image process 500 proceeds toblock 506 after block 504. At block 506, the target tool image process500 determines whether the position of the actual welding-type tool 104is more than a threshold distance from the position of the target toolimage 604. This check may be helpful to make sure that the target toolimage 604 does not get too far away from the actual welding-type tool104, so as to minimize the detrimental impact associated with such asituation. In some examples, the precise value of the threshold distancemay be stored in helmet memory circuitry and/or be editable as part ofthe custom configurations at block 502.

In the example of FIG. 5 , the target tool image process 500 proceeds toblock 508 after block 506 if the position of the actual welding-typetool 104 is more than a threshold distance from the position of thetarget tool image 604. At block 508, the target tool image process 500determines whether to reset the target tool image 604 to anearlier/later time and/or position that is closer to the position of theactual welding-type tool 104. In some examples, this determination mayinvolve notifying the operator 106 (or an administrator) of thedisparity in positions and/or prompting for a decision whether to reset.In some examples, the target tool image process 500 may be configured(e.g., at block 502) to default to reset (or not reset) in the absenceof response to the reset prompt.

In the example of FIG. 5 , the target tool image process 500 proceeds toblock 510 after block 508 if the target tool image process 500determines to reset (e.g., based on a received input or default) thetarget tool image 604 to an earlier time and/or position closer to thewelding-type tool 104. In some examples, the target tool image process500 may provide an output (e.g., via the helmet I/O device(s) 208)notifying the operator 106 of the reset before and/or after the resetoccurs. At block 510, the target tool image process 500 adjusts thescore(s) of the weld training simulation based on the reset. In someexamples, this may serve as a way to account for the negative scoringimpact of failing to match the target position of the target tool image604 if no reset were available. In some examples, the score(s) may benegatively impacted each time there is a reset, such as by a decrease ofa portion (e.g., one third/half/full) of a letter grade or a portion(e.g., 5%, 10%, 15%, etc.) of a numerical score. In some examples, thenegative impact may increase (e.g., from −5% to −15%) each reset, everyother reset, or after a certain number of resets.

In the example of FIG. 5 , the target tool image process 500 proceeds toblock 512 after block 510. At block 512, the target tool image process500 modifies its configuration (and/or the target welding techniqueparameters) to reset the target tool image 604. For example, the targettool image process 500 may revert the target tool image 604 to anearlier position along the weld bead/path. As another example, thetarget tool image process 500 may revert the target tool image 604 to aposition (and/or other target welding technique parameters)corresponding to an earlier (e.g., arc) time. In some examples, thetarget tool image process 500 may revert the target tool image 604 to atime or position that would place the target tool image 604 closest tothe position of the welding-type tool 104. In some examples, the targettool image process 500 may revert the target tool image 604 to a time orposition that would place the target tool image 604 closest to a point athreshold distance away from the welding-type tool 104.

In some examples, the target tool image process 500 may further adjustthe travel speed of the target tool image 604 at block 512. This mayhelp the operator 106 better keep up with the target tool image 604. Insome examples, the target tool image process 500 may reduce the travelspeed of the target tool image 604 (e.g., by some fraction and/orpercentage). In some examples, the target tool image process 500 may setthe travel speed of the target tool image 604 to match that of thewelding-type tool 104. In some examples, the target tool image process500 may keep track of the number of resets, progressively decrease thetravel speed (e.g., from ¾ speed, to ½ speed, to ⅓ speed, etc.) for eachreset, up to a threshold number of resets, at which point the travelspeed of the target tool image 604 is set to match that of thewelding-type tool 104. In some examples, the threshold number of resets,the speed decrease progression, and/or the placement of the target toolimage 604 at reset may be set as part of the configuration of block 502.

In the example of FIG. 5 , the target tool image process 500 returns toblock 504 after block 502. As shown, the target tool image process 500proceeds to block 514 after block 508 if the target tool image process500 decides not to reset the target tool image 604. As shown, the targettool image process 500 also proceeds to block 514 after block 506 if theposition of the actual welding-type tool 104 is not more than athreshold distance from the position of the target tool image 604.

At block 506, the target tool image process 500 displays the target toolimage 604 on the display screen(s) 602 of the welding helmet 200 (asshown, for example, in FIGS. 6 a-6 d ). In some examples, the targettool image process 500 may determine a display location for the targettool image 604 on the display(s) 602 of the welding helmet 200 prior todisplay at block 514. In some examples, the determination of the displaylocation may involve a translation based on the sensor data and/orposition/orientation data relating to the welding helmet 200 (from block404). For example, the target tool image process 500 may use the knownposition and/or orientation of the target tool image 604 relative to theworkpiece 108, and the known position and/or orientation of the weldinghelmet 200 (and/or its display screen(s)) relative to the workpiece 108,and translate this information into an appropriate display location forthe target tool image 604. In some examples, the target tool imageprocess 500 may also determine a display location for, and/or display, atarget weld bead 606 (and/or weld path), using the same (or a similar)process (see, e.g., FIGS. 6 a-6 d ).

In the example of FIG. 5 , the target tool image process 500 proceeds toblock 516 after block 514. At block 516, the target tool image process500 outputs one or more additional feedback effects (and/or simulationstimuli) if the actual welding technique parameters (e.g., determined atblock 408) are the same as (or within a threshold of) the target weldingtechnique parameters. In some examples, the target tool image process500 may output a different effect for each congruent actual/targetwelding technique parameter. In some examples, the target tool imageprocess 500 may only output an effect if a certain number (or all) ofthe actual welding technique parameters are the same as (or within athreshold of) the target welding technique parameters. In some examples,one or more additional images may also be output (e.g., a smiling emoji,a check mark, fireworks, etc.).

In some examples, the additional feedback effects may indicate to theoperator 106 that they are properly positioning and/or orienting thewelding-type tool 104. In some examples, the effects may include adarkening, emboldening, and/or highlighting of the (e.g., outline ofthe) target tool image 604. For example, the (e.g., outline of the)target tool image 604 may change color (e.g., to green) or becomeanimated (e.g., pulsing). As another example, the target tool imageprocess 500 may change the (e.g., outline of the) target tool image 604to one color (e.g., green) when the actual/target welding techniqueparameters are the same (or within a threshold), change to a secondcolor (e.g., yellow) when the actual/target welding technique parametersare different (e.g., by more than the threshold), and/or change to athird color (e.g., red) when the actual/target welding techniqueparameters are very different (e.g., by more than second threshold). Insome examples, the target tool image process 500 may change thetransparency and/or darkness of the target tool image 604 in addition(or as an alternative) to the color, so that the target tool image 604appears to fade away as it gets farther (e.g., more than a 1^(st),2^(nd), 3^(rd), etc. threshold) away from the actual welding-type tool104. In some examples, the thresholds discussed above with respect toblock 516 may be set and/or configured as part of block 502.

In the example of FIG. 5 , the target tool image process 500 proceeds toblock 518 after block 516. At block 518, the target tool image process500 determines whether it should end or not. In some examples, thisdetermination may coordinate with the determination at block 414 of theweld training simulation process 400. As shown, the target tool imageprocess 500 ends if the target tool image process 500 determines itshould end, and otherwise proceeds back to block 504 if the target toolimage process 500 determines it should not end.

FIGS. 6 a-6 d illustrate example depictions of a target tool image 604on a display screen 602 of the welding helmet 200. Also shown aredepictions of an actual welding-type tool 104, a target weld bead 606,an actual weld bead 608, a workpiece 108, and two examples of scores614. The target weld bead 606 is shown as a transparent outline alongthe joint of the workpiece 108. The target tool image 604 is shown as atransparent outline in the same shape as the welding-type tool 104.

In some (e.g., live-weld) examples, the workpiece 108 and/orwelding-type tool 104 seen in FIGS. 6 a-6 d may be unaltered images of areal live welding-type tool 104 and/or workpiece 108 seen through thedisplay screen 602, or captured from a helmet (e.g., camera) sensor 202and displayed on the display screen 602. In some (e.g., simulated weld)examples, the welding-type tool 104 and/or workpiece 108 may be enhancedand/or altered when displayed on (or seen through) the display screen602, so as to lend credibility to the simulation.

In the example of FIG. 6 a , the welding operation is just beginning.The welding-type tool 104 is shown just beginning to weld at the startof the target weld bead 606. As shown, the target tool image 604 is atthe same position as the actual welding-type tool 104 (since this is thebeginning). However, the target tool image 604 has a differentorientation than the welding-type tool 104, which results in differenttarget/actual technique parameters (e.g., travel angle, work angle, aim,contact tip to work distance, etc.). As shown, the scores 614 have beenimpacted by the difference in orientation by decreasing slightly fromthe 100% and/or A+ starting point.

In the example of FIG. 6 b , the welding operation has progressed a bitfrom the beginning shown in FIG. 6 a . As shown, the welding-type tool104 has moved farther along the target weld bead 606 from the start.However, the target tool image 604 has moved much farther than thewelding-type tool 104, to almost the end of the target weld bead 606.With the positions of the target tool image 604 and the actualwelding-type tool 104 so incongruent and/or out of synch, it isdifficult to tell whether the orientations are also incongruent and/orout of synch, and thus less useful as a guidance mechanism. As shown,the scores 614 have also been negatively impacted by the incongruity.Indeed, the positions are so different that the operator 106 has beenpresented with a reset option 610 (e.g., block 508), which the operator106 may be able to select using voice or a special input on thewelding-type tool 104 itself, to avoid interrupting the weldingoperation.

In the example of FIG. 6 c , the welding operation has progressed alittle more from FIG. 6 b , and the target tool image 604 has been resetto the position of the actual welding-type tool 104. As shown, thescores 614 have been negatively impacted from the reset of the targettool image 604. Nevertheless, with the two positions closer together, itis easier to tell that the orientation of the actual welding-type tool104 is different than that of the target tool image 604.

In the example of FIG. 6 d , the welding operation has progressed alittle more from FIG. 6 c , and the operator 106 has managed to matchthe position and orientation of the welding-type tool 104 with thetarget tool image 604. As shown, the outline of the target tool image604 has been emboldened via an additional feedback effect (e.g., block516) to let the operator 106 know that the positions/orientations of thewelding-type tool 104 and target tool image 604 are congruent and/orsynchronized. An additional smiley face emoji 612 is also shown toemphasize the positivity of the congruency and/or synchronization, andthe scores 614 have been similarly positively impacted. In someexamples, there may be a further effect that shows the precise impact onthe score (e.g., +10).

The ability of the target tool image process 500 to reset the positionof the target tool image 604 to a position closer to the actualwelding-type tool 104 may help in minimizing the risk that an operator106 will overcompensate to try and catch up with the target tool image604; a practice which may be highly detrimental to the quality of theweld. Additionally, resetting the target tool image 604 to a positioncloser to the welding-type tool 104 may allow an operator 106 to betterperceive and/or understand differences in orientation and/or othertechnique parameters. While a reset may have a negative impact on score,the reset may also increase the chance the operator 106 will be able tothereafter synchronize the welding-type tool 104 with the target toolimage 604, which may have a positive impact on score.

The present methods and/or systems may be realized in hardware,software, or a combination of hardware and software. The present methodsand/or systems may be realized in a centralized fashion in at least onecomputing system, or in a distributed fashion where different elementsare spread across several interconnected computing or cloud systems. Anykind of computing system or other apparatus adapted for carrying out themethods described herein is suited. A typical combination of hardwareand software may be a general-purpose computing system with a program orother code that, when being loaded and executed, controls the computingsystem such that it carries out the methods described herein. Anothertypical implementation may comprise an application specific integratedcircuit or chip. Some implementations may comprise a non-transitorymachine-readable (e.g., computer readable) medium (e.g., FLASH drive,optical disk, magnetic storage disk, or the like) having stored thereonone or more lines of code executable by a machine, thereby causing themachine to perform processes as described herein.

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. Therefore, it is intendedthat the present method and/or system not be limited to the particularimplementations disclosed, but that the present method and/or systemwill include all implementations falling within the scope of theappended claims.

As used herein, “and/or” means any one or more of the items in the listjoined by “and/or”. As an example, “x and/or y” means any element of thethree-element set {(x), (y), (x, y)}. In other words, “x and/or y” means“one or both of x and y”. As another example, “x, y, and/or z” means anyelement of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z),(x, y, z)}. In other words, “x, y and/or z” means “one or more of x, yand z”.

As utilized herein, the terms “e.g.,” and “for example” set off lists ofone or more non-limiting examples, instances, or illustrations.

As used herein, the terms “coupled,” “coupled to,” and “coupled with,”each mean a structural and/or electrical connection, whether attached,affixed, connected, joined, fastened, linked, and/or otherwise secured.As used herein, the term “attach” means to affix, couple, connect, join,fasten, link, and/or otherwise secure. As used herein, the term“connect” means to attach, affix, couple, join, fasten, link, and/orotherwise secure.

As used herein the terms “circuits” and “circuitry” refer to physicalelectronic components (i.e., hardware) and any software and/or firmware(“code”) which may configure the hardware, be executed by the hardware,and or otherwise be associated with the hardware. As used herein, forexample, a particular processor and memory may comprise a first“circuit” when executing a first one or more lines of code and maycomprise a second “circuit” when executing a second one or more lines ofcode. As utilized herein, circuitry is “operable” and/or “configured” toperform a function whenever the circuitry comprises the necessaryhardware and/or code (if any is necessary) to perform the function,regardless of whether performance of the function is disabled or enabled(e.g., by a user-configurable setting, factory trim, etc.).

As used herein, a control circuit may include digital and/or analogcircuitry, discrete and/or integrated circuitry, microprocessors, DSPs,etc., software, hardware and/or firmware, located on one or more boards,that form part or all of a controller, and/or are used to control awelding process, and/or a device such as a power source or wire feeder.

As used herein, the term “processor” means processing devices,apparatus, programs, circuits, components, systems, and subsystems,whether implemented in hardware, tangibly embodied software, or both,and whether or not it is programmable. The term “processor” as usedherein includes, but is not limited to, one or more computing devices,hardwired circuits, signal-modifying devices and systems, devices andmachines for controlling systems, central processing units, programmabledevices and systems, field-programmable gate arrays,application-specific integrated circuits, systems on a chip, systemscomprising discrete elements and/or circuits, state machines, virtualmachines, data processors, processing facilities, and combinations ofany of the foregoing. The processor may be, for example, any type ofgeneral purpose microprocessor or microcontroller, a digital signalprocessing (DSP) processor, an application-specific integrated circuit(ASIC), a graphic processing unit (GPU), a reduced instruction setcomputer (RISC) processor with an advanced RISC machine (ARM) core, etc.The processor may be coupled to, and/or integrated with a memory device.

As used, herein, the term “memory” and/or “memory device” means computerhardware or circuitry to store information for use by a processor and/orother digital device. The memory and/or memory device can be anysuitable type of computer memory or any other type of electronic storagemedium, such as, for example, read-only memory (ROM), random accessmemory (RAM), cache memory, compact disc read-only memory (CDROM),electro-optical memory, magneto-optical memory, programmable read-onlymemory (PROM), erasable programmable read-only memory (EPROM),electrically-erasable programmable read-only memory (EEPROM), acomputer-readable medium, or the like. Memory can include, for example,a non-transitory memory, a non-transitory processor readable medium, anon-transitory computer readable medium, non-volatile memory, dynamicRAM (DRAM), volatile memory, ferroelectric RAM (FRAM),first-in-first-out (FIFO) memory, last-in-first-out (LIFO) memory, stackmemory, non-volatile RAM (NVRAM), static RAM (SRAM), a cache, a buffer,a semiconductor memory, a magnetic memory, an optical memory, a flashmemory, a flash card, a compact flash card, memory cards, secure digitalmemory cards, a microcard, a minicard, an expansion card, a smart card,a memory stick, a multimedia card, a picture card, flash storage, asubscriber identity module (SIM) card, a hard drive (HDD), a solid statedrive (SSD), etc. The memory can be configured to store code,instructions, applications, software, firmware and/or data, and may beexternal, internal, or both with respect to the processor.

The term “power” is used throughout this specification for convenience,but also includes related measures such as energy, current, voltage, andenthalpy. For example, controlling “power” may involve controllingvoltage, current, energy, and/or enthalpy, and/or controlling based on“power” may involve controlling based on voltage, current, energy,and/or enthalpy.

As used herein, welding-type power refers to power suitable for welding,cladding, brazing, plasma cutting, induction heating, carbon arccutting, and/or hot wire welding/preheating (including laser welding andlaser cladding), carbon arc cutting or gouging, and/or resistivepreheating.

As used herein, a welding-type power supply and/or power source refersto any device capable of, when power is applied thereto, supplyingwelding, cladding, brazing, plasma cutting, induction heating, laser(including laser welding, laser hybrid, and laser cladding), carbon arccutting or gouging, and/or resistive preheating, including but notlimited to transformer-rectifiers, inverters, converters, resonant powersupplies, quasi-resonant power supplies, switch-mode power supplies,etc., as well as control circuitry and other ancillary circuitryassociated therewith.

1. A non-transitory machine readable medium comprising machine readableinstructions which, when executed by a processor, cause the processorto: determine a first target position and a first target orientation fora target tool image based on one or more target welding techniqueparameters; identify an actual position and an actual orientation of awelding tool based on sensor data received from a sensor of a weldingheadgear; compare the actual position of the welding tool with the firsttarget position of the target tool image; and in response to determiningthe first target position of the target tool image is more than athreshold distance from the actual position of the welding tool: reset,or provide an option to reset, the first target position of the targettool image to a second target position that is closer to the actualposition of the welding tool.
 2. The non-transitory machine readablemedium of claim 1, further comprising machine readable instructionswhich, when executed by the processor, cause the processor to displaythe target tool image on a display screen of the welding headgear basedon the first target position or the second target position.
 3. Thenon-transitory machine readable medium of claim 2, further comprisingmachine readable instructions which, when executed by the processor,cause the processor to display a movement of the target tool image onthe display screen at a travel speed that corresponds to an actualtravel speed of the welding tool.
 4. The non-transitory machine readablemedium of claim 1, further comprising machine readable instructionswhich, when executed by the processor, cause the processor to negativelyadjust a welding score in response to the first target position beingreset.
 5. The non-transitory machine readable medium of claim 4, whereinthe welding score is determined based on a difference between the firsttarget orientation of the target tool image and the actual orientationof the welding tool, as well as a number of times the first targetposition of the target tool image was reset.
 6. The non-transitorymachine readable medium of claim 1, wherein the one or more targetwelding technique parameters were recorded during a previous weldingoperation.
 7. The non-transitory machine readable medium of claim 6,wherein the second target position of the target tool image correspondsto a position that was recorded during the previous welding operation.8. A welding headgear, comprising: a display screen; a sensor configuredto detect sensor data relating to a welding tool; and processingcircuitry configured to: identify a length of a weld bead; determine afirst target position and a first target orientation for a target toolimage based on the length of the weld bead and one or more targetwelding technique parameters recorded during a previous weldingoperation, identify an actual position and an actual orientation of thewelding tool based on the sensor data, compare the actual position ofthe welding tool with the first target position of the target toolimage, and in response to determining the first target position of thetarget tool image is more than a threshold distance from the actualposition of the welding tool: reset, or provide an option to reset, thefirst target position of the target tool image to a second targetposition that is closer to the actual position of the welding tool, thesecond target position of the target tool image corresponding to aposition of a previous welding tool that was recorded during theprevious welding operation when a previous weld bead was of a samelength as the length of the weld bead.
 9. The welding headgear of claim8, wherein the one or more target welding technique parameters compriseone or more of a torch position, torch orientation, torch travel speed,torch travel direction, torch travel angle, work angle, contact tip towork distance, torch aim, or weld path characteristic.
 10. The weldingheadgear of claim 8, wherein the processing circuitry is furtherconfigured to negatively adjust a welding score in response to the firsttarget position being reset.
 11. The welding headgear of claim 8,further comprising a helmet shell, the display screen, sensor, andprocessing circuitry being retained by the helmet shell.
 12. The weldingheadgear of claim 8, wherein the sensor comprises a camera sensor,optical sensor, infra-red (IR) sensor, thermal sensor, acoustic sensor,ultrasonic sensor, or electromagnetic sensor.
 13. The welding headgearof claim 8, wherein the target tool image comprises an outline,transparent depiction, translucent depiction, or semi-transparentdepiction of the welding tool, a different welding tool, or a weldingconsumable.
 14. The welding headgear of claim 8, wherein the processingcircuitry is further configured to: compare the actual position andactual orientation of the welding tool with the first target positionand first target orientation of the target tool image, and in responseto determining the actual position and actual orientation of the weldingtool match the first target position and first target orientation of thetarget tool image, providing an effect that affirms that the weldingtool is properly positioned and oriented.
 15. A method of guiding awelding operator, comprising: determining, via processing circuitry of awelding headgear, a first target position and a first target orientationfor a target tool image based on one or more target welding techniqueparameters; identifying an actual position and an actual orientation ofa welding tool based on sensor data received from a sensor of thewelding headgear; comparing the actual position of the welding tool withthe first target position of the target tool image; in response todetermining the first target position of the target tool image is morethan a threshold distance from the actual position of the welding tool:resetting, or providing an option to reset, the first target position ofthe target tool image to a second target position that is closer to theactual position of the welding tool; displaying the target tool image ona display screen of the welding headgear based on the first targetposition or second target position; negatively adjusting a welding scorein response to the first target tool position being reset; anddisplaying the welding score on the display screen.
 16. The method ofclaim 15, wherein the sensor comprises a camera sensor, optical sensor,infra-red (IR) sensor, thermal sensor, acoustic sensor, ultrasonicsensor, or electromagnetic sensor.
 17. The method of claim 15, whereinthe target tool image comprises an outline, transparent depiction,translucent depiction, or semi-transparent depiction of the weldingtool, a different welding tool, or a welding consumable.
 18. The methodof claim 15, further comprising displaying a movement of the target toolimage on the display screen at a travel speed that corresponds to anactual travel speed of the welding tool.
 19. The method of claim 15,wherein: the one or more target welding technique parameters compriseone or more of a torch position, torch orientation, torch travel speed,torch travel direction, torch travel angle, work angle, contact tip towork distance, torch aim, or weld path characteristic.
 20. The method ofclaim 15, further comprising: comparing the actual position and actualorientation of the welding tool with the first target position and firsttarget orientation of the target tool image; and in response todetermining the actual position and actual orientation of the weldingtool match the first target position and first target orientation of thetarget tool image, providing an effect, via a user interface of thewelding headgear, that affirms that the welding tool is properlypositioned and oriented.